Cowl: Service and Repair

Windshield Lower Panel Replacement


Removal Procedure

Caution:Refer to Approved Equipment for Collision Repair Caution .

1.Disable the SIR system. Refer to SIR Disabling and Enabling .

2.Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .





3.Remove all related panels and components.

4.Repair as much of the damage as possible to factory specifications.

Caution:Refer to Foam Sound Deadeners Caution .

5.Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .





Important:Do not damage any inner panels or reinforcements.

1.Locate and drill out all factory welds. Note the number and location of welds for installation of the windshield frame side panel.





1.Using a grinder or an equivalent tool, remove the silicon bronze welds at the upper windshield frame side panel and header location.





1.Remove the damaged windshield frame side panel.

Installation Procedure





1.Drill 8 mm (5/16 in) plug weld holes in the service part as necessary at the locations noted from the original windshield frame side panel.

2.Prepare all mating surfaces as necessary.

3.Apply GM-approved Weld-Thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair .





1.Position the windshield frame side panel to the vehicle. Use 3-dimensional measuring equipment to ensure fit. Clamp the panel into place.





Important:Use either metal inert gas (MIG) or silicon bronze for welding the windshield frame side panel.

1.Using either a MIG or silicon bronze welder, weld the outer ends of the windshield frame side panel, duplicating the factory welds.





1.Using a MIG welder, plug weld as necessary, duplicating the factory welds.

2.Clean and prepare all welded surfaces.

3.Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .

4.Paint the repair area. Refer to Paint Identification Paint Identification .

5.Install all related panels and components.

6.Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

7.Enable the SIR system. Refer to SIR Disabling and Enabling .